Zero waste to landfill. There hasn't been a more sought-after factory accessory since fluffy dice in the forklift cab. Nestlé, Toyota, GM, Pepsico, Mars and Tyco are just some of the big industry players promoting their zero waste credentials.
The philosophy is defined by the Zero Waste International Alliance as: "designing and managing products and processes to systemically avoid and eliminate the volume and toxicity of waste and materials". Which roughly translates into manufacturing parlance as: 'eradicate all non-hazardous waste being sent to landfill'.
Targeting zero waste is akin to putting the average factory waste management strategy on steroids. Waste eradicated before it even arrives at goods in or repurposed and sold for profit for reuse in other parts of the supply chain. Immunity from landfill taxes, soaring employee engagement from waste reduction work and a CSR boost worthy of a standing ovation from the marketing department.
Zero to landfill offers the lot by changing the focus of your waste management activity (see figure). Exponents target the elimination and reuse of waste among the upper echelons of the waste hierarchy, while novices ponder the recycling and recovery elements at its base.
Climbing the waste hierarchy to reach zero waste
Those reaching for a grappling hook, take five. The road to zero waste to landfill begins by the recycle bins in the factory car park. Andrew Griffiths, environmental sustainability manager at Nestle UK, who has helped all 13 of Nestlé's UK sites attain zero waste to landfill status, explains: "The first thing is to understand what your key waste streams are. You should be looking to assess the scale of each waste stream and what's driving them."
Whether you discover steams that are a trickle or a torrent: the next move is to appoint a waste partner, recommends Griffiths. "Engage a waste partner who can help you move forward with your goal, someone who can provide you with the infrastructure you need. Look for an organisation with a high level of capability and a strong network of partners. These must all be fully auditable and you should check their credentials. The other thing is working with an organisation that is passionate about moving up the waste hierarchy. That's really worth its weight in gold as they can help you hunt for new opportunities"
Scrutinise your waste partner closely advises Jim Rutherford and John Hickson, who head the facilities, utilities and environmental team at Vauxhall's zero to landfill Ellesmere Port plant. ""We've dug and dug until we're satisfied." says Rutherford. "We'll go out on duty of care audits to visit where the waste goes."
'But they told me' or 'we didn't think we needed to check that' will carry short shrift from magistrates, who can impose fines of up to £5,000 on businesses failing to adopt a duty of care over waste disposal. Crown Courts can impose unlimited fines and prison sentences of up to five years. Be warned ? only fools rush in says Rutherford. "When appointing a waste partner you should make yourself a checklist, know what you're looking for in terms of the licensing and go and check on the Environment Agency website. It's your waste and ignorance is not a defence."
Segregation and the shopfloor
Once your concerns are satisfied then your chosen waste partner should provide the necessary bins and bailers. That leaves you responsible for bringing the most influential piece of equipment in any landfill free bid: your people. "We had a grassroots team that went out and engaged with employees," explains Peter Osborne, plant manager at Scott Safety, Skelmersdale, which secured zero landfill status last July. "The team had a manager in place to guide them but was employee-led. They would be out on the production floor looking at the flow of the waste and assessed what bins and recycling points we had in place and what was and wasn't working. I think that's why it was so successful because we had the engagement at that level."
For the Skelmersdale team, success was something personal. All employees had signed a banner committing them to achieving zero landfill status explains Osborne. "I read about the idea in a book by zero defects quality guru Phil Crosby. We thought it was a great way to get people to show commitment to the cause."
Vauxhall built buy-in to zero landfill through a network of environmental champions across key business units explains Hickson. "The idea is those people will feedback any issues with segregation of waste or any other environmental issues. They can also answer people's queries about 'why do I need to put this plastic cap in that colour bin'. Once people have got that answer, good intentions spread around. Segregation just becomes part of the culture"
As evidenced by the end of opaque recycling bins at Ellesmere Port. "Two years ago we decided to put out bin stands with a coloured lid and a clear plastic sack," explains Hickson."The idea is that you can see at a glance if anybody has contaminated that waste stream at source. It cost us a few quid in terms of plastic bags but in terms of getting the message across we're serious about segregation, it's worth every penny. "
Of course, waste can still stray into the wrong sack reflects Hickson. But it's quickly detected via area audits held weekly at the plant. And, upon discovery, it's not unusual for the most senior member of the inspection team to delve in and deal with the mistake. Hickson says: "You feel a bit of a fool dipping your way in the bin at the time, but if someone sees you doing that as part of the leadership team then they understand that this is serious."
Imitation is the sincerest form of flattery and the facilities team have found themselves inundated with shopfloor ideas suggestions since first targeting zero landfill in 2008 explains Hickson. One initiative was to overhaul the process for extracting sealant used in vehicle assembly, explains Rutherford. "The sealant is removed from drums using a giant plunger and would always leave a residual amount in the bottom of barrels. We had a suggestion to extend the stroke of the plunger which has significantly improved the yield."
It's an example of shifting mindsets towards reducing or eliminating waste that is the nub of the zero waste thinking.Segregation provides a trail for management to follow back to the source and sort. Vauxhall, for example, eliminates excess packaging by insisting suppliers deliver materials according to specifications set out in a GM packaging design manual explains Hickson.
"You give them the requirements what kind of cardboard do you want? Dual wall, tri-wall. How are they going to band it? What kind of pallet are they going to use? We agree that upfront."
Not all waste streams are born equal
Follow your different waste streams and you soon discover that not all were born equal. Osborne of Scott Safety explains: "Our first project that took us up to 98% landfill free was all about cardboard, plastics and paper. That final 2% was predominantly based around things like food waste, some sanitary waste and also landscaping waste. To get that final 2% is difficult and involved working together with our waste contactor to understand what we needed to do on our side in order to enable them to help us a achieve the zero landfill."
Those stubborn slurries and awkward adhesives are where the best waste management firms really prove their worth says Rutherford of Vauxhall. "It's about finding a waste management partner who won't just put your waste in the ground but has the commitment to find you the outlets to get you to landfill free."
It's an iterative journey that might take years. Vauxhall took seven to reach landfill free at Ellesmere Port. Scott Safety, Skelmersdale took three, Nestle two and Pepsico, Peterlee less than a year. Ultimately, time isn't the right measure.
Zero waste, like climbing Mount Everest, is all about making it to the top. Choose a shrewd guide, a hardy party of volunteers and lead the expedition with an indomitable spirit. Then, whatever the shape or size of your factory; the summit should be within your grasp. "It is attainable, there are solutions there," says Osborne. "It is having the resource, desire and commitment to make it something that you want to happen. " Sentiments echoed by fellow club zero landfill member, Hickson of Vauxhall. "My gut feeling is that anyone can achieve this with the right commitment. "But, if you are not looking to get there then you never will."
